Abstract: An induction coil is described for wireless charging of a vehicle battery. The induction coil includes a first electrically conductive strip, a second electrically conductive strip, and a first electrically insulative strip between the first and second electrically conductive strips. The first electrically insulative strip electrically isolates the first electrically conductive strip from the second electrically conductive strip. The first electrically conductive strip, the first electrically insulative strip, and the second electrically conductive strip are integrated into stack, where the stack is configured as multiple windings. The first and second electrically conductive strips are adapted to conduct an alternating current. Alternating current flow through the first and second electrically conductive strips and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery.

Abstract: An electric current sensor for detecting a leakage current from an electric vehicle charger. The current sensor includes a magnetic core having a gap formed therein, a first conductor wound around the magnetic core to form a first coil, a second conductor wound around the magnetic core to form a second coil, and a tunnel-magnetoresistance (TMR) sensor element arranged in the gap of the magnetic core. A difference between electric current flow in the first and second conductors produces a magnetic field in the gap of the magnetic core proportional to a leakage current, and the magnetic field produces a voltage in the TMR sensor element indicative of a value of the leakage current.

Abstract: An electric current sensor for detecting a leakage current from an electric vehicle charger. The current sensor includes a magnetic core having a gap formed therein, a first conductor wound around the magnetic core to form a first coil, a second conductor wound around the magnetic core to form a second coil, and a tunnel-magnetoresistance (TMR) sensor element arranged in the gap of the magnetic core. A difference between electric current flow in the first and second conductors produces a magnetic field in the gap of the magnetic core proportional to a leakage current, and the magnetic field produces a voltage in the TMR sensor element indicative of a value of the leakage current.

Abstract: An induction coil for wireless charging of a vehicle battery is described. The induction coil includes an electrically conductive tube configured as multiple windings, and an electrically conductive coupler configured for attachment to the electrically conductive tube. The electrically conductive tube and the electrically conductive coupler are adapted to conduct an alternating current. Alternating current flow in the tube and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery. The electrically conductive tube and the electrically conductive coupler are each configured for passage of a coolant therethrough. A coolant flow through the electrically conductive tube transfers heat from the electrically conductive tube generated by alternating current flow through the electrically conductive tube.

Abstract: An induction coil for wireless charging of a vehicle battery is described. The induction coil includes an electrically conductive tube configured as multiple windings, and an electrically conductive coupler configured for attachment to the electrically conductive tube. The electrically conductive tube and the electrically conductive coupler are adapted to conduct an alternating current. Alternating current flow in the tube and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery. The electrically conductive tube and the electrically conductive coupler are each configured for passage of a coolant therethrough. A coolant flow through the electrically conductive tube transfers heat from the electrically conductive tube generated by alternating current flow through the electrically conductive tube.

Abstract: An induction coil is described for wireless charging of a vehicle battery. The induction coil includes a first electrically conductive strip, a second electrically conductive strip, and a first electrically insulative strip between the first and second electrically conductive strips. The first electrically insulative strip electrically isolates the first electrically conductive strip from the second electrically conductive strip. The first electrically conductive strip, the first electrically insulative strip, and the second electrically conductive strip are integrated into stack, where the stack is configured as multiple windings. The first and second electrically conductive strips are adapted to conduct an alternating current. Alternating current flow through the first and second electrically conductive strips and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery.

Abstract: A charging pad for an electric vehicle includes a coolant assembly, a magnetics assembly, and an electronics assembly. The coolant assembly has a top wall and a bottom wall which form a coolant channel for circulating coolant through the coolant assembly. The magnetics assembly is configured to wirelessly receive power from a charging source induction coil arrangement facing the magnetics assembly. The magnetics assembly is adjacent the bottom wall of for heat generated by the magnetics assembly to thermally conduct from the bottom wall into coolant in the coolant channel. The electronics assembly is configured to convert the power wirelessly received by the magnetics assembly into electrical power for charging the electric vehicle. The electronics assembly is arranged adjacent the top wall for heat generated by the electronics assembly to thermally conduct from the top wall into coolant in the coolant channel.

Abstract: A wireless charging unit for an electric vehicle is provided with a metal enclosure to shield a high-power switching noise environment enclosed within the unit. A wireless power transfer system includes the wireless charging unit on the electric vehicle side that receives power wirelessly from a charging base. In addition to a high-power switching network, the wireless charging unit may include a wireless communication system for wirelessly communicating control messages to the charging base. The metal enclosure may include a cutout region having a plastic cover underneath which an antenna may be mounted to establish wireless communication with the charging base from within the metal enclosure.

Abstract: An assembly includes a metallic housing, an electromagnetic (EM) device, and a bobbin in which the EM device is supported. The bobbin has a non-metallic, inner bobbin body, a non-metallic, outer bobbin body, and a metallic shield sandwiched between the inner and outer bobbin bodies. The EM device and the bobbin are mounted in the housing with the bobbin being between the EM device and the housing for heat from the EM device to thermally conduct through the inner and outer bobbin bodies and the shield to the housing while the shield shields noise of the EM device from the housing.

Abstract: A wireless charging unit for an electric vehicle is provided with a metal enclosure to shield a high-power switching noise environment enclosed within the unit. A wireless power transfer system includes the wireless charging unit on the electric vehicle side that receives power wirelessly from a charging base. In addition to a high-power switching network, the wireless charging unit may include a wireless communication system for wirelessly communicating control messages to the charging base. The metal enclosure may include a cutout region having a plastic cover underneath which an antenna may be mounted to establish wireless communication with the charging base from within the metal enclosure.

Abstract: A bus bar for use in conducting an alternating current may comprise multiple substantially parallel ribs and an electrically conductive attachment feature. Each rib may include a first and second end. Each rib may be provided for conducting a substantially equal portion of the current. The ribs may be spaced apart to provide gaps therebetween for airflow through the gaps. The electrically conductive attachment feature may connect the first ends of the plurality of ribs, and may be provided for attaching the plurality of ribs to an electrical component. An electrically insulating spacer may be located between at least two of the ribs, contacting and providing physical support to those ribs.

Abstract: A charging pad includes a housing, an interface layer, a magnetics assembly, and an electronics assembly. The housing has a magnetics assembly housing part and an electronics assembly housing part. The interface layer is within the housing. The magnetics assembly is arranged below the interface layer within the magnetics assembly housing part and the electronics assembly is arranged above the interface layer within the electronics assembly housing part.

Abstract: An assembly includes a metallic housing, an electromagnetic (EM) device, and a bobbin in which the EM device is supported. The bobbin has a non-metallic, inner bobbin body, a non-metallic, outer bobbin body, and a metallic shield sandwiched between the inner and outer bobbin bodies. The EM device and the bobbin are mounted in the housing with the bobbin being between the EM device and the housing for heat from the EM device to thermally conduct through the inner and outer bobbin bodies and the shield to the housing while the shield shields noise of the EM device from the housing.

Abstract: A charging pad includes a housing, an interface layer, a magnetics assembly, and an electronics assembly. The housing has a magnetics assembly housing part and an electronics assembly housing part. The interface layer is within the housing. The magnetics assembly is arranged below the interface layer within the magnetics assembly housing part and the electronics assembly is arranged above the interface layer within the electronics assembly housing part.

Abstract: A charging pad for an electric vehicle includes a coolant assembly, a magnetics assembly, and an electronics assembly. The coolant assembly has a top wall and a bottom wall which form a coolant channel for circulating coolant through the coolant assembly. The magnetics assembly is configured to wirelessly receive power from a charging source induction coil arrangement facing the magnetics assembly. The magnetics assembly is adjacent the bottom wall of for heat generated by the magnetics assembly to thermally conduct from the bottom wall into coolant in the coolant channel. The electronics assembly is configured to convert the power wirelessly received by the magnetics assembly into electrical power for charging the electric vehicle. The electronics assembly is arranged adjacent the top wall for heat generated by the electronics assembly to thermally conduct from the top wall into coolant in the coolant channel.

Abstract: A bus bar for use in conducting an alternating current may comprise multiple substantially parallel ribs and an electrically conductive attachment feature. Each rib may include a first and second end. Each rib may be provided for conducting a substantially equal portion of the current. The ribs may be spaced apart to provide gaps therebetween for airflow through the gaps. The electrically conductive attachment feature may connect the first ends of the plurality of ribs, and may be provided for attaching the plurality of ribs to an electrical component. A method for manufacturing a bus bar for use in conducting an alternating current may comprise attaching a plurality of electrically conductive strips to form a bus bar having a plurality of ribs, each rib having a first and second end, the ribs spaced apart to provide gaps therebetween for airflow through the gaps, the first ends of the plurality of ribs connected together.

Abstract: An automotive headlamp assembly having a closed-loop cooling circuit. The headlamp assembly includes a housing cooperating with a transparent lens cover to define a chamber. At least one light source is located within the chamber. The cooling circuit has at least one cold plate thermally coupled to the light source. A radiator is fluidly coupled to the cold plate by a plurality of tubes. The tubes are oriented at least partially upwardly and configured to circulate a fluid through the cooling circuit as a result of heating and cooling of the fluid therein.

Abstract: An automotive headlamp assembly having a closed-loop cooling circuit. The headlamp assembly includes a housing cooperating with a transparent lens cover to define a chamber. At least one light source is located within the chamber. The cooling circuit has at least one cold plate thermally coupled to the light source. A radiator is fluidly coupled to the cold plate by a plurality of tubes. The tubes are oriented at least partially upwardly and configured to circulate a fluid through the cooling circuit as a result of heating and cooling of the fluid therein.

Abstract: An automotive headlamp assembly having a closed-loop cooling circuit. The headlamp assembly includes a housing cooperating with a transparent lens cover to define a chamber. At least one light source is located within the chamber. The cooling circuit has at least one cold plate thermally coupled to the light source. A radiator is fluidly coupled to the cold plate by a plurality of tubes. The tubes are oriented at least partially upwardly and configured to circulate a fluid through the cooling circuit as a result of heating and cooling of the fluid therein.

Abstract: An automotive headlamp assembly having a closed-loop cooling circuit. The headlamp assembly includes a housing cooperating with a transparent lens cover to define a chamber. At least one light source is located within the chamber. The cooling circuit has at least one cold plate thermally coupled to the light source. A radiator is fluidly coupled to the cold plate by a plurality of tubes. The tubes are oriented at least partially upwardly and configured to circulate a fluid through the cooling circuit as a result of heating and cooling of the fluid therein.